Apparatus for metal melting



March 29, 1949. K. MARSH 2,465,545

APPARATUS FOR METAL MELTING Filed lay 10, 1946 2 Sheets-Sheet 1 w l l N 9 N INVENTOR K IR TLA ND NA RSH ATTORNEY K. MARSH APPARATUS FOR METAL MELTING March 29; 1949.

2 Sheets-Sheet 2 Filed May 10, 1946 w M a T N N m ww T I/NY Patented Mar. 29, 1949 2,465,545 APPARATUS FOR METAL MELTING Kirtland Marsh, Pittsburgh, Pa... mmum Company of America,

assignor to Alu- Pittsburgh, Pa.,

a corporation of Pennsylvania Application May 10, 1946, Serial No. 668,904

, Claims.

The present invention relates in general to apparatus for melting metals, and is particularly concerned with furnace structures suitable for melting, remelting and/or reclaiming readily oxidizable metals, such as aluminum, magnesium and alloys thereof, existing in the form of finely divided scrap metal composed of scalpings, borings, chips, turnings, saw dust, foil, finely divided powders, together with such larger and heavier charges as discarded castings sprues, gates, runners and partial or whole ingots.

The recovery of scrap metal in general normally requires its remelting. In the remelting of light metal scrap, it is well known to introduce the fine aggregate of such scrap below the surface of a body of molten metal in order to avoid excessive metal losses by reason of oxidation, and to utilize the furnace heat to drive off volatilizable substances contaminating the scrap metal without subjecting the same to the open flame of the heat producing medium within the furnace. Known recovery apparatus has usually incorporated submersible charging tubes extending below the surface of a molten metal bath. It is also well known to agitate molten metal to submerse finely divided scrap therebelow in reclamation processes.

The furnace structures of the art, however, have not taught reclaiming metal made up from scrap of varying weights and densities at one and the same time. it having been normal practice to separately melt the fine or light weight scrap and heavier scrap in separate furnaces, thereby exposing the scrap to double melting, with attendant oxidation and handling losses.

It is an object of the present invention to provide an improved apparatus for producing a uniform grade of metal from scrap of varying degrees of bulk and weight.

It is a further object to provide an improved apparatus for continuously melting metal of varying weight and bulk with a minimum amount of loss due to oxidation during the melting operation.

It is a further object of the present invention to provide means for producing molten metal from scrap metal of varying weight including a fine aggregate, such as borings, scalpings, foil, turnings, saw dust and the like, and heavier stock, such as ingots, croppings, sprues, gates, discarded castings, and the like.

A further object is to provide a metal melting furnace incorporating a scrap submerging chamber in association with a furnace hearth and fore-1 hearth for receiving scrap at separated locations in accordance with its weight and bulk.

Another object is to provide a furnace structure that incorporates mechanical means for submerging light weight scrap with a minimum exposure to oxidation, as well as means for receiving heavy and bulky metal.

Other objects will be apparent from a consideration of the description in the following specification, as pointed out in the appended claims.

The annexed drawings and the following description set forth in detail certain means for carrying out the invention, such disclosed means illustrating a preferred form in which the principle of the invention may be successfully practiced.

In the drawings:

Fig. 1 represents a furnace structure in sectional plan view embodying the characteristics of the present invention;

Fig. 2 represents a sectional view of the furnace structure illustrated in Fig. 1, with part thereof broken away, and taken along the line 11-11 thereof; and

Fig. 3 represents a sectional view of the furnace structure illustrated in Fig. land taken along the line III-III thereof.

The improved furnace structures for carrying out the practice of the present invention make it possible to melt or remelt scrap metal wherein the total charge of metal is fed to a furnace at two separated charging points. Fine aggregate of the charge, normally fioatable upon the surface of the molten metal, is mechanically submerged in a forehearth forming an integral part of the main furnace hearth. Heavy scrap is fed into a portion of the forehearth removed from interference with the mechanical scrap submerger. Both forms of the charged scrap are subjected to the influence of the temperature of the molten metal within the main furnace hearth,

which is maintained in circulation between the main and forehearths through the medium of the aforementioned mechanical scrap submerging mechanism.

The design and arrangement of the forehearth and main hearth, together with their associated elements to be hereinafter more fully described, are such that the light weight scrap, readily oxidizable in the case of aluminum, magnesium and their alloys, is intermittently or continuously fed and mechanically submerged beneath the molten metal surface in a substantially closed chamber forming a portion of the forehearth. The bulky and heavy scrap is charged into an open portion c of. the forehearth out 3 of contact with the mechanical submerging mechanism. Communication ducts between the forehearth and main hearth, under the action of the mechanical scrap submerger, set up circulatory flow of the molten metal within the furnace and forehearth to maintain a melt of uniform consistency and insure flow of the relatively hot molten metal from the main hearth through the forehearth.

Referring to the drawings, reference numeral l represents a furnace constructed from exterior steel and interior fire brick, or suitable insulation, in accordance with well recognized principles of furnace design. Attached to the furnace l0, and preferably forming an integral part thereof, is an enclosed chamber l2, which extends outwardly from the main hearth l4 of the furnace and communicates therewith through a duct or opening IS in a wall of furnace I0. Chamber l2 has formed, as an integral extension thereof, an open top channel IS in communication with chamber mits dross floating on the molten metal to be circulated into the main hearth for skimming purposes. Charging of the furnace is accomplished by melting down the metal of a previous charge left within the furnace ill, or by chargin scrap or virgin metal into the furnace and melting the same through the combustion of fuel and/or gases emanating from burners projecting into the furnace in through apertures 24.

The light weight, or normally floatablescrap ispreferably fed into the stand pipe or chute 38 in any suitable manner, or through door 23. in-

I2 through an aperture or duct I8, as well as in communication with the main hearth I4 through opening or duct 20.

Chamber l2 and open top trough l6 combine to constitute a forehearth which occupies substantially the length of one side wall of furnace I0, chamber I2 being enclosed within the brick and steel structure defining walls and roof thereof, and the trough portion 16 being open to the atmosphere over its top surface.

The furnace I0 is preferably provided with end doors 2|, 22 and 23, and burner openings 24, ducts 25 and 26 through the side wall of the furnace I 0, opposite to that of the forehearth, being provided in communication with fiues or stacks 21 and 28, respectively. for purposes of carrying off gases and products of combustion within the furnace hearth I 4. In the preferred form of the structure of this invention, two additional fiues (not shown), one at each end of the furnace, are usually provided, all of the fiues being preferably designed to enter a common stack or flue, a'portion of one stack being shown at 29, Fig. 3. The furnace floor 3|, including the floor 32 in the forehearth, is generally sloped towards the furnace wall in which drain spout is located whereby the furnace and forehearth may be drained as desired. Also, a tapping spout (not shown), is normally provided at an elevation slightly higher than the drain spout for tapping ofl? the molten charge for subsequent use in the production of castings, or to a holding pot or ladle prior to use in casting procedures. The diagonal broken lines appearing in the forehearth l4 (Fig. 1) represent the intersection of floor termitte'ntly or by a continuous conveyor (not shown), and is immediately submerged by paddle members 35 (shown in Fig. 2 in full lines in scrap submerging position and in broken lines in raised entry position), which are adapted to rotate in a clockwise direction, as viewed in Fig. 2. Stand-pipe 36 is preferably provided with a hinged cap 40 that may be closed during intermittent charging. Simultaneously therewith, or as desired, heavy, normally sinkable scrap is charged into the open trough l 6, preferably above the station represented by the broken line rectangle in Fig. 1, where it gravitationally SinKS to the bottom of the forehearth. Circulation of the molten metal will follow the directional arrows illustrated on Fig. 1, the molten metal being drawn into chamber 12 through aperture l5 and propelled outwardly therefrom through opening l8 into trough Hi, from where it will flow over the stand at some lower temperature since this chame her is not directly exposed to the burners of the main hearth. An aperture l9, however, has been surfaces generally sloping towards the furnace corporate a door or aperture sealing member have been found entirely satisfactory for adaptation to the chamber ll of this invention.

In the operation of the furnace structure hereinabove described. molten metal is acquired within the furnace and forehearth structure, preferably up to a minimum level which seals off the duct IS. The remaining communicating ducts l8 and 20 are preferably not submerged, which perfound beneficial, and permits flow of heat from and is not exposed to the high temperature or open flame of-the main hearth.

The circulation of the melt into trough l6 sets up a flow over th bulky, heavy charge within this trough which, in effect, is a washing action by the hot molten metal which serves to melt down this heavy scrap.

The need for exposing the chamber I: to atmospheric conditions is practically eliminated once the apparatus is set in operation and the process gets under way, further eliminating any undue exposure of the light weight scrap which is more susceptible to oxidation in view of its large surface area, as compared to heavy scrap in block or equivalent form, fed to the trough Hi.

It will also be appreciated that normal fiuxing methods may be incorporated in the furnace designs herein contemplated, solid or gaseous fluxing media having been found satisfactory in installations of this type. Metal skimming operations can likewise be carried out, the doors 2|, 22 and 23 being useful for this purpose.

Other apparatus, not specifically disclosed in the specification, will present themselves to those 'skilled in this art. The invention, then, is not to be limited to the precise disclosure given hereinin the appended claims.

What is claimed is: t

1. In a mechanism of the class described, a main furnace hearth provided with heating means for melting and retaining molten metal therein, an enclosed chamber in communication with the furnace hearth, an open top trough in communication with said hearth and enclosed chamber, said open trough and enclosed chamber constituting a forehearth out of direct contact with said heating means, and means within said enclosed chamber for circulating molten metal through said main hearth, enclosed chamber and open trough.

2. In a mechanism of the class described, a main furnace hearth provided with burners for melting metal therein, a forehearth out of direct contact with the burners and in molten metal circulation and communication with the main hearth, a portion of said forehearth being enclosed and a portion thereof being of open trough-like construction, and mechanical means installed within said enclosed portion of the forehearth for submerging light weight scrap admitted thereto, said mechanical means being also adapted to circulate the molten metal through the enclosed portion of the forehearth, open trough and main hearth.

-3. A mechanism of the class described comprising a main furnace hearth, a forehearth, interconnecting ducts between said main and torehearth, said main hearth being substantially closed and equipped with heat producing means to maintain a relatively high metal-melting temperature therein, said iorehearth being divided into two chambers, one of which is substantially closed to atmospheric conditions and the other having an open top, an interconnecting duct between the two forehearth chambers, means for charging light weight scrap metal to said enclosed forehearth chamber, said open iorehe'arth chamber being adapted to receive heavy scrap metal, and mechanical means within the enclosed iorehearth chamber for submerging the light weight scrap metal beneath the surface of molten metal in said enclosed forehearth chamber while establishing circulation of the molten metal through the main hearth and both chambers of the iorehearth.

4. A scrap metal remelting furnace comprising a main hearth and a forehearth, said main hearth having burner means installed therein, said forehearth having a portion thereof substantially enclosed and an open trough portion, ducts connecting the main hearth with the forehearth, a duct connecting the two portions of the forehearth, and means associated with the enclosed portion of the forehearth tor submerging light weight scrap charged thereto, said scrap submerging means being also adapted to circulate molten metal through the main hearth and both portions of the forehearth. 1

5. A scrap metal remelting furnace comprising a main hearth and a iorehearth, burner means i n said main hearth for maintaining a molten metal bath, an enclosed chamber portion in said forehearth adapted to receive light weight scrap charged thereto, an open trough portion in said iorehearth adapted to receive heavy weight scrap charged thereto, a communicating duct interconnecting the chamber and open trough portions of said Iorehearth, communicating ducts interconnecting each of the iorehearth portions with the main hearth, and molten metal circulating means installed in said chamber portion of the forehearth for drawing molten metal from the main hearth and recirculating the same. through the open trough portion of the forehearth back to the main hearth. KIRTLAND MARSH.

REFERENCES CITED The following references are of record in the 

